Method for producing a disc roll

Abstract

A disc roll includes a plurality of annular disc members each defining a hole and having a peripheral surface; and a rotary shaft fitted into the holes of the annular disc members by insertion, whereby the peripheral surfaces of the disc members serve as a conveying surface of the disc roll. The disc members include an inorganic fiber, mica and a clay having a content of particle components that have a particle size of 5 μm or larger of not higher than 30% by weight based on the weight of the clay.

The invention claimed is: 
     
       1. A method for producing a disc roll, comprising the steps of:
 forming into a plate form a slurry raw material to obtain a disc member base material, said slurry raw material comprising an inorganic fiber, mica and a kibushi clay containing particle components that have a particle size of 5 μm or larger in an amount of 30% by weight or less based on the weight of the kibushi clay; 
 stamping out a plurality of annular disc members each defining a hole and having a peripheral surface, from said disc member base material; and 
 fitting said plurality of annular disc members on a rotary shaft by insertion through the holes and fixing said disc members thereon to obtain a disc roll, whereby the peripheral surface of said disc members serves as a conveying surface of the disc roll, 
 wherein the kibushi clay is either elutriated or subjected to a wet sizing separation purification process, and the kibushi clay is configured to be sintered by heat applied thereto upon use of the disc roll to give a hardening action, 
 wherein said kibushi clay has a content of impurities of 10% by weight or less based on the weight of the clay, 
 wherein said inorganic fiber is present in an amount of 20 to 40% by weight based on the total weight of said disc members, and said kibushi clay is present in an amount of 20 to 40% by weight based on the total weight of said disc members, and 
 wherein said mica is present in an amount of 20 to 35% by weight based on the total weight of the disc member. 
 
     
     
       2. The method according to  claim 1 , wherein said formation of the disc member base material is conducted by a paper-making process. 
     
     
       3. The method for producing a disc roll according to  claim 1 , wherein said mica is muscovite. 
     
     
       4. The method for producing a disc roll according to  claim 1 , wherein the amount of said kibushi clay is 30 to 40% by weight based on the total weight of said disc members. 
     
     
       5. The method for producing a disc roll according to  claim 1 , wherein said kibushi clay has a content of particles with a particle size of 5 μm or larger of not higher than 15% by weight based on the weight of the kibushi clay. 
     
     
       6. The method for producing a disc roll according to  claim 1 , wherein said mica has an average particle size of 5 to 500 μm. 
     
     
       7. A method of making a plate-shaped disc member base material comprising an inorganic fiber, mica and a kibushi clay having a content of particle components that have a particle size of 5 μm or larger of not higher than 30% by weight based on the weight of the kibushi clay, the method comprising:
 either elutriating the kibushi clay or subjecting the kibushi clay to a wet sizing separation purification process, 
 forming a disc roll from a plurality of annular disc members formed with the plate-shaped disc member base material, 
 configuring the kibushi clay to be sintered by heat applied thereto upon use of the disc roll formed therefrom to give a hardening action, and 
 providing said kibushi clay with a content of impurities of 10% by weight or less based on the weight of the clay, 
 wherein said inorganic fiber is present in an amount of 20 to 40% by weight based on the total weight of said disc member base material, and said kibushi clay is present in an amount of 20 to 40% by weight based on the total weight of said disc member base material, and wherein said mica is present in an amount of 20 to 35% by weight based on the total weight of the disc member base material. 
 
     
     
       8. The method according to  claim 7 , wherein said mica is muscovite. 
     
     
       9. The method according to  claim 7 , wherein the amount of said kibushi clay is 30 to 40% by weight based on the total weight of said disc member base material. 
     
     
       10. The method according to  claim 7 , wherein said kibushi clay has a content of particles with a particle size of 5 μm or larger of not higher than 15% by weight based on the weight of the kibushi clay. 
     
     
       11. The method according to  claim 7 , wherein said mica has an average particle size of 5 to 500 μm. 
     
     
       12. A method for producing a glass using a disc roll as a conveying roll,
 wherein the disc roll comprises a plurality of annular disc members each defining a hole and having a peripheral surface and a rotary shaft fitted into the holes of said annular disc members by insertion, whereby the peripheral surface of said disc members serves as a conveying surface of the disc roll, 
 wherein said disc members comprises an inorganic fiber, mica and a kibushi clay containing particle components that have a particle size of 5 μm or larger in an amount of 30% by weight or less based on the weight of the kibushi clay, 
 wherein the kibushi clay being either elutriated or subjected to a wet sizing separation purification process, and the kibushi clay being configured to be sintered by heat applied thereto upon use of the disc roll to give a hardening action, 
 wherein said kibushi clay has a content of impurities of 10% by weight or less based on the weight of the clay, 
 wherein said inorganic fiber is present in an amount of 20 to 40% by weight based on the total weight of said disc members, and said kibushi clay is present in an amount of 20 to 40% by weight based on the total weight of said disc members, and 
 wherein said mica is present in an amount of 20 to 35% by weight based on the total weight of the disc members.